Patent Application
20220184460
The present invention generally relates to golf balls having covers with decorative-effect coatings. The outer cover surface can have surface textured dimples and a decorative-effect first coating can be applied to this outer surface. A transparent second coating can be applied over the decorative-effect coating. In another embodiment, a semi-transparent metallic first coating overlies the outer cover surface and a decorative-effect second coating overlies the metallic coating. The resulting golf balls have unique and appealing appearances.
Both professional and amateur golfer use multi-piece, solid golf balls today. Basically, a two-piece solid golf ball includes a solid inner core protected by an outer cover. The inner core is normally made of a natural or synthetic rubber such as polybutadiene, styrene butadiene, or polyisoprene. The cover surrounds the inner core and can be made of a variety of materials including ethylene acid copolymer ionomers, polyamides, polyesters, polyurethanes, and polyureas.
Three-piece, four-piece, and even five-piece balls have become more popular over the years. More golfers are playing with these multi-piece balls for several reasons including new manufacturing technologies, lower material costs, and desirable ball playing performance properties. Many golf balls used today have multi-layered cores comprising an inner core and at least one surrounding outer core layer. For example, the inner core may be made of a relatively soft and resilient material, while the outer core may be made of a harder and more rigid material. The “dual-core” sub-assembly is encapsulated by a single or multi-layered cover to provide a final ball assembly. Different materials are used in these golf ball constructions to impart specific properties and playing features to the ball.
For instance, ionomer compositions comprising an ethylene acid copolymer containing acid groups that are at least partially neutralized can be used to make golf ball covers. Suitable ethylene acid copolymers that may be used to form the cover layers are generally referred to as copolymers of ethylene; C3 to C8 α, β-ethylenically unsaturated mono-or dicarboxylic acid; and optional softening monomer. Commercially available ionomer compositions that can be used to make such covers include Surlyn® (DuPont) and Escor® and Iotek® (Exxon) ionomers. In recent years, there has been high interest in using thermoset and thermoplastic polyurethane compositions to make golf ball covers. Different molding operations can be used to form the cover over the core or sub-assembly of the ball. For example, compression-molding, casting, and injection-molding processes can be use.
After the golf balls have been removed from the mold, they are normally subjected to finishing steps including flash-trimming, surface-treatment, marking, and application of coatings. Optical brighteners can be included in the cover stock material used to make the cover layer, in primer coatings, in paints, and in topcoat compositions. When applied to the exterior of a golf ball, optical brighteners enhance the whiteness and/or brightness of such balls. Clear topcoats are often applied to the cover of the golf ball. The topcoats protect the ball and any underlying clear or pigmented layers. The topcoats also protect any trademarks, tradenames logos, and other indicia printed on the ball. The topcoats normally have a high gloss finish.
Golf balls are available today in a wide variety of colors such as, for example, white, yellow, orange, green, red, and pink. In recent years, manufacturers have looked at developing golf balls having special decorative effects. For example, Morgan et al., U.S. Patent Application Publication 2004/0176188 discloses golf ball comprising a core, a cover, and at least one intermediate layer therebetween. The intermediate layer includes pigment which contributes to the color of the ball and the cover is at least partially transparent such that the intermediate layer is at least partially visible. The cover also comprises an optical enhancer such as a florescent dye, optical brightener or an optical active chemical additive.
Sullivan et al., U.S. Pat. No. 9,295,882 discloses a golf ball comprising a core and composite layer, wherein the composite layer comprises a fibrous material dispersed in a translucent polymer matrix. An outer translucent cover layer is preferably disposed about the composite layer.
Comeau et al., U.S. Pat. No. 9,433,826 discloses a golf ball comprising a substrate layer that is formed from a thermoset or thermoplastic composition and having an outer surface that is pre-modified with a catalytic coating; a metallic film that is formed about the outer surface by contacting the catalytic coating with a mixture comprising: (i) at least one aqueous and/or organic aerosol comprising at least one metal in cationic/oxidizing form; and (ii) at least one reducing agent; and a layer surrounding the metallic film that is formed from a thermoset or thermoplastic composition.
Although some special decorative-effect golf balls have been developed, there is still a need for new, aesthetically-pleasing golf balls. The golf balls should be cost-effective and be capable of being produced in a wide variety of colors. The golf balls should have a distinctive look when viewed at different viewing angles. The present invention provides such golf balls. The finished golf balls have a unique and appealing look along with other advantageous features and benefits.
The present invention generally relates to golf balls having unique and appealing appearances. The golf balls are fashionable and decorative and available in a wide variety of colors. In one embodiment, a golf ball comprising a core having at least one layer and a cover having at least one layer is provided, wherein the cover comprises: i) an outer surface having dimples disposed thereon, at least a portion of the dimples comprising a perimeter and an inner surface, wherein the inner surfaces comprise at least one indented or protruding member, ii) a semi-transparent decorative-effect first coating overlying the outer surface of the cover, the decorative-effect coating comprising a color-shifting pigment such that the pigment has a first color at a first viewing angle and a second color different from the first color at a second viewing angle; and iii) a transparent second coating overlying the decorative-effect first coating.
The golf ball dimples can have different surface texturing and patterns. For example, the inner surfaces of the dimples may comprise at least one indented channel, particularly at least two indented channels, wherein the channels are linear and at least two of the channels have the same channel length and channel width. In another example, the dimple inner surfaces comprise at least one indented sub-dimple. In yet another example, the dimple inner surfaces comprise at least one protruding ridge. The decorative-effect coating may comprise a decorative material selected from the group consisting of phosphorescent pigments, luminescent pigments, light-reflective pigments, metallic pigments, pearlescent pigments, edge-effect pigments, color pigments and dyes, and mixtures thereof. In one example, the decorative-effect coating has a thickness in the range of about 0.1 μm to about 50 μm.
In another embodiment, the golf ball comprises a core having at least one layer and a cover having at least one layer, wherein the cover comprises: i) an outer surface having dimples disposed thereon, the dimples overlying a layer comprising a series of protruding members that provide a concavo-convex pattern; ii) a semi-transparent metallic first coating overlying the outer surface of the cover, the metallic coating comprising a metallic pigment; and iii) a transparent second coating overlying the metallic first coating. In one particular example, the semi-transparent metallic coating provides a decorative design on the outer surface of the cover, wherein the decorative design appears and disappears depending upon the viewing angle. The semi-transparent metallic coating may comprise a metallic pigment selected from the group consisting of aluminum, titanium dioxide, iron oxide, and zinc pigments, metal-oxide coated mica pigments, and mixtures thereof. In one example, the mica pigments are coated with titanium oxide or iron oxide. In another example, the metallic coating comprises a pigment mixture composition of: (a) a metal-oxide coated mica pigment in an amount of about 5 wt. % to about 50 wt. %; and (b) titanium dioxide-coated aluminum pigment in an amount of about 50 wt. % to about 95 wt. %. The metallic coating may comprise the pigment mixture composition in an amount of about 1% to about 30 wt. % based on total solids in the semi-transparent metallic coating. In yet another example, the metallic coating further comprises a metal film. The metallic coating may comprise a decorative material selected from the group consisting of phosphorescent pigments, luminescent pigments, edge-effect pigments, color pigments and dyes and mixtures thereof. In one example, the metallic coating has a thickness in the range of about 0.1 μm to about 50 μm.
In yet another embodiment, the golf ball comprises a core having at least one layer and a cover having at least one layer, wherein the cover comprises: i) an outer surface having dimples disposed thereon, the dimples overlying a layer comprising a series of protruding members that provide a concavo-convex pattern; ii) a semi-transparent metallic first coating overlying the outer surface of the cover; iii) a semi-transparent decorative-effect second coating overlying the metallic first coating, wherein the decorative-effect coating comprises a decorative material selected from the group consisting of color-shifting pigments, phosphorescent pigments, luminescent pigments, light-reflective pigments, metallic pigments, pearlescent pigments, edge-effect pigments, color pigments and dyes, and mixtures thereof; and iv) a transparent third coating overlying the decorative-effect second coating. In one example, the decorative material is a color-shifting pigment such that the pigment has a first color at a first viewing angle and a second color different from the first color at a second viewing angle. In another example, the decorative material is a light-reflective white pigment or a pearlescent pigment.
The novel features that are characteristic of the present invention are set forth in the appended claims. However, the preferred embodiments of the invention, together with further objects and attendant advantages, are best understood by reference to the following detailed description in connection with the accompanying drawings in which:
Golf balls having various constructions may be made in accordance with this invention. For example, golf balls having two-piece, three-piece, and four-piece constructions with single or multi-layered cover materials may be made. Representative illustrations of such golf ball constructions are provided and discussed further below. The term, “layer” as used herein means generally any spherical portion of the golf ball. More particularly, in one version, a two-piece golf ball containing a core with a surrounding cover is made. Three-piece golf balls containing a dual-layered core and single-layered cover also can be made. The dual-core includes an inner core (center) and surrounding outer core layer. In another version, a four-piece golf ball containing a dual-core and dual-cover (inner cover and outer cover layers) is made. In yet another construction, a four-piece or five-piece golf ball containing a dual-core; casing layer(s); and cover layer(s) may be made. As used herein, the term, “casing layer” means a layer of the ball disposed between the multi-layered core assembly and cover. The casing layer also may be referred to as a mantle or intermediate layer. The diameter and thickness of the different layers along with properties such as hardness and compression may vary depending upon the construction and desired playing performance properties of the golf ball.
Golf balls generally include a spherical outer surface with a plurality of dimples formed thereon. In conventional golf balls, the dimples are normally spherical dimples with circular plan shapes that help reduce drag and increase lift of the golf ball. In general, dimples are formed in the golf ball surface as recesses or indentations. These dimples are formed where a dimple wall slopes away from the outer surface of the ball, thus forming the depression. Multiple dimples are distributed at close spacing over the outer surface of the golf ball. The cross-sectional shape of dimples is defined by a portion of a curved surface such as a circle, ellipse or hyper-ellipse. Dimple cross-sectional shapes also include straight surfaces such as, for example, conical, conical frustum, spherical-polygonal dimples, and the like. Referring to
In
Historically, dimple patterns for golf balls have had a variety of geometric shapes, patterns, and configurations. Primarily, patterns are laid out in order to provide desired performance characteristics based on the particular ball construction, material attributes, and player characteristics influencing the ball's initial launch angle and spin conditions. Therefore, dimple pattern development is a secondary design step that is used to achieve the appropriate aerodynamic behavior, thereby tailoring ball flight characteristics and performance attributes.
In attempts to improve aerodynamic symmetry, many dimple patterns have been developed based on geometric shapes. These may include circles, hexagons, triangles, and the like. Other dimple patterns are based in general on the five Platonic Solids including icosahedron, dodecahedron, octahedron, cube, or tetrahedron. Yet other dimple patterns are based on the thirteen Archimedian Solids, such as the small icosidodecahedron, rhomicosidodecahedron, small rhombicuboctahedron, snub cube, snub dodecahedron, or truncated icosahedron. Furthermore, other dimple patterns are based on hexagonal dipyramids. Dimple properties such as number, shape, size, volume, edge angles and arrangement are often manipulated in an attempt to generate a golf ball that has improved aerodynamic properties.
The outer surface of the golf balls of this invention can have various surface texturing. This surface textured outer surface of the golf ball can have various surface patterns and be referred to as the base or sub-coating layer. The base layer is coated with a semi-transparent metallic coating, and/or a decorative effect coating, and/or a transparent topcoat as described further below. The combination of the base layer and coating layers provides a special aesthetic effect to the golf ball also as described further below. By “surface texturing” as used herein, it is meant forming indentations or protrusions within the dimple, or on the non-dimpled (land) surface of the outer surface of the golf ball, or both within the dimple and the non-dimpled land surface. For example, as described above and shown in
These indentations or protrusions can be arranged randomly or in geometric order. For example, the indented or protruding members can be arranged in a grid or lattice. These indented members may be in any suitable form such as, for example, indentations, groves, channels, tunnels, cavities, recessed portions, depressions, and the like. The protruding members also may be in any suitable form such as, for example, ridges, bumps, nubs, hooks, juts, ribs, segments, brambles, ribs, spines, points, projections, extensions, raised members, and the like. The indentations and protrusions may have any suitable shape and dimensions. For example, the protrusions may have a circular, oval, triangular, square, rectangular, pentagonal, hexagonal, heptagonal, or octagonal shape. Conical-shaped protrusions also may be used. The indentations and protrusions may be arranged in linear or non-linear patterns such as arcs and curves. The indentations and protrusions may be configured so there are gaps or channels located between them. These indentations and protrusions can be arranged so the inner surface of the dimple has a series of peaks and valleys.
Different surface texturing of the dimples may be used in accordance with the present invention. For example, Sullivan, U.S. Pat. No. 6,569,038, the disclosure of which is hereby incorporated by reference, discloses a golf ball having dimples with structures therein to energize or agitate the airflow over the dimpled surface to increase the aerodynamic performance of the ball. These structures include sub-dimples and radiating convex or concave arms emanating from the center of the dimple. As shown generally in
In another embodiment, the golf ball can have one or more channels or ridges on its surface as described in Sullivan et al., U.S. Pat. No. 8,137,216, the disclosure of which is hereby incorporated by reference. These channels or ridges may be linear, or may be curved, and may or may not fully circumscribe the golf ball. The channels may or may not intersect other channels. These channels or ridges may also be combined with traditional or non-traditional dimples. In one example, referring to
In another example, the non-dimpled, land area is surface-textured. Morgan et al., U.S. Pat. No. 8,329,081, the disclosure of which is hereby incorporated by reference, discloses a method of forming a golf ball with secondary surface texture created on the fret (land) areas of a ball. The secondary surface texture is created on the golf ball hob prior to the primary dimples being formed into the hob. When the dimples are formed, they largely obliterate the secondary surface texture except for the fret area and the perimeter of the dimples.
In Aoyama et al., U.S. Pat. No. 8,808,113, the disclosure of which is hereby incorporated by reference, the golf ball has one or more bands or channels on its surface. The bands form spherical polygonal tiles having a system of variable width and/or height/depth ridges or channels on the golf ball surface. The channels may be straight or curved, may or may not circumscribe the golf ball. The channels may also be discontinuous. The channels may or may not intersect other channels. The channels may cover as much of the ball surface as desired, up to virtually 100%, but preferably the surface coverage of the channels is less than about 40%. The outer surface of the golf ball may include other surface patterns such as, for example, dimples with different surface texturing and conventional dimples as described above.
In one embodiment, as illustrated in
In Madson et al., U.S. Pat. No. 10,758,784, the disclosure of which is hereby incorporated by reference, dimples incorporating linear channels having a channel length (L) and a channel width (CW) are disclosed. In a preferred embodiment of the invention, the outer surface of the golf ball comprises less than 360 dimples and all of the dimples incorporate directional surface texturing made up of substantially linear arrangements that are aligned. The linear arrangements, like the linear channels (50) disclosed in
As described above, the outer surface of the golf ball of this invention may contain dimples that have been surface textured or a non-dimpled (land) surface that has been surface textured or combinations thereof. The surface textured dimples may be combined with conventional dimples to form the outer surface of the ball. Preferably, a golf ball according to the present invention has an outer surface comprising a plurality of dimples covering greater than 70 percent of the outer surface and at least 20 percent of the dimples incorporate surface texturing.
Referring to
In
As described above, the outer surface of the golf balls of this invention can have various surface patterns. The golf balls of this invention can be produced in a wide variety of colors, such as white, yellow, orange, green, red, and pink, and are typically colored by painting the outer surface of the ball, or by incorporating pigment directly into the cover composition. As described further below, a semi-transparent metallic coating, and/or a decorative effect coating, and/or a transparent topcoat can be applied to the surface textured outer surfaces of the golf ball. This combination of layers provides a unique, visually distinct appearance as described further below. The resulting golf balls of this invention reflect light in a much more random, less uniform manner than prior art golf balls. The golf balls of this invention are aesthetically pleasing and provide a creative look.
As show in
As used herein, a “semi-transparent” or “translucent” layer preferably has an average transmittance of visible light (e.g., between about 380 nm and about 770 nm or alternately between about 400 nm and about 700 nm) of less than about 80% and preferably about 75% or less, and the underlying layer is not completely hidden.
As used herein, a “clear” or “transparent” layer preferably has an average transmittance of visible light (e.g., between about 380 nm and about 770 nm or alternately between about 400 nm and about 700 nm) of at least about 80% or greater and preferably about 90% or greater. The average transmittance referred to herein is typically measured for incident light normal (i.e., at approximately 90°.) to the plane of the object and can be measured using any known light transmission apparatus and method, e.g., a UV-Vis spectrophotometer. The semi-transparent metallic layer may have a variety of visible light transmissions depending on the brightness (reflectivity) and the like of the base layer.
The term “flip-flop properties” refers to appearance performance by which a pattern appears and disappears due to a concavo-convex shape on the outer surface of the ball. For example, complex design patterns including multiple stripes can appear in a visible area around a center of the golf ball, however, stripe patterns and other designs can disappear in an invisible area adjust to the visible area.
In another embodiment, the semi-transparent metallic layer may be a thin metal film containing a metal selected from aluminum, nickel, gold, platinum, chromium, iron, copper, tin, indium, silver, titanium, lead, zinc, germanium, or the like, or alloys or compounds of the same, formed by vacuum deposition, sputtering, ion plating, or the like.
The semi-transparent metallic coating layer may have a thickness of about 0.1 μm to about 50 μm. In preferred embodiments, the semi-transparent metallic layer coating may have a thickness of about 1 μm to 45 μm, or about 2 μm to 40 μm or about 4 μm to 30 μm. These coating layers have a thickness that is considerably less than the polymeric layers used to construct a traditional golf ball, for example, two-piece, three-piece, four-piece, and five-piece golf balls as described above. Semi-transparent metallic coating layers having a thickness in this range tend to have a good balance between reflecting and transmitting the incident light. In this way, the semi-transparent metallic coating layer helps impart unique visual effects to the golf ball construction of this invention.
As show in
The effect pigments include absorption pigments, metal effect pigments, and pearlescent pigments. Absorption pigments represent true colors, as they absorb part of the light that hits them and scatter the rest. This phenomenon gives them their own body color. In contrast, metal effect pigments reflect almost all the light like lots of tiny mirrors. This gives them their high surface luster. Pearlescent pigments have a layered structure so that light is reflected at different levels in the pigment. The reflected waves interfere with each other and this creates a brilliant interference color.
In one preferred embodiment, color-shifting pigments can be used in the visual effect layer. Color-shifting pigments that have a first color at a first angle of incident light or viewing and a second color different from the first color at a second angle of incident light or viewing. Such color-shifting pigments are disclosed in Phillips et al., U.S. Pat. No. 7,235,300, the disclosure of which is hereby incorporated by reference.
Various other visual effect materials can be used in accordance with the present invention. For example, metallics, fluorescents, optical brighteners, pearlescents, phosphorescents, luminescents, edge-effect pigments, pigments, dyes and/or tinting agents can be dispersed in the decorative effect layer.
Metallics include any suitable metal, but lustrous metals with a high aspect ratio are preferred. Metallics may be in the form of flakes, filler, chopped fiber, or whiskers. Metallics may also comprise iridescent glitter and metallized film. The metallic particles preferably have faces that have an individual reflectance of over 75%, more preferably at least 95%, and most preferably 99-100%. For example, flat particles with two opposite faces can be used.
Titanium dioxide pigment is preferably used as light-reflective material, because of its light scattering properties including reflectivity and refraction. As the light strikes the surface of the composition, most of the light will be reflected because of the titanium dioxide pigment concentration. The light strikes the surface of the pigment (which has a relatively high refractive index in contrast to the binder resin), the light is bent and reflected outwardly. The portion of light which is not reflected will pass through the particles and will be bent in different direction. Other useful metal (or metal alloy) flakes, plates, powders, or particles may include bismuth boron, brass, bronze, cobalt, copper, nickel, chrome, iron, molybdenum, nickel powder, stainless steel, zirconium aluminum, tungsten metal, beryllium metal, zinc, or tin. Other metal oxides may include zinc oxide, iron oxide, aluminum oxide, magnesium oxide, zirconium oxide, and tungsten trioxide.
Metalized films and foils, particularly metalized polyester films and aluminum foil, and glitter specks, which comprises very small plastic pieces painted in metallic, neon, and iridescent colors to reflect light also can be used as reflective fillers in accordance with this invention.
The particle size of the metallic particles should be relatively small. The particle size preferably is 0.1 mm-1.0 mm more preferably 0.2 mm-0.8 mm, and most preferably 0.25 mm-0.5 mm. The quantity of metallic particles may vary widely, as it will depend upon the desired effect and is best determined experimentally. In general, an aesthetically pleasing reflective appearance can be obtained by using about 0.1-10, or more preferably 1-4, parts by weight metallic particles in the polymeric material. Metallics such as aluminum flakes, vapor-deposited aluminum flakes, metal oxide-coated aluminum flakes, or colored aluminum flakes can be used.
Pearlescent pigments also can be used in the decorative-effect coating layer. Such pigments attempt to mimic the inherent gleam and luster of natural pearls. This is achieved by utilizing the light reflection characteristics of microscopic platelets and the optimization of their diffraction and diffusion properties. There are several types of pearl pigments commercially available, including natural pearl essence, bismuth oxychloride crystals, and oxide-coated micas. There are also several other types of substrates that can be oxide coated, such as glass flakes and alumina plates. Preferably, platelets of mica that are coated with thin layers of titanium dioxide (TiO2) and/or iron oxide, and the like are used. The broad face of the platelets can range from 4 microns to 1,000 microns across and are approximately 0.5 microns thick, although synthetic micas can achieve thicknesses of less than 0.25 microns. The platelets of coated mica are very smooth, so they are light reflective while maintaining a high degree of transparency, which means only a portion of the light is reflected. The portion that is not reflected is transmitted through the platelet to the next layer where it. can be further reflected.
In one embodiment, a pigment mixture composition of: (a) a mica-based luster pigment consisting of a metal oxide coated mica in an amount of from about 5 wt. % to about 50 wt. %; and (b) titanium dioxide-coated alumina in an amount of from about 50 wt. % to about 95 wt. % is used. Such mixtures are described in Hogge et al., U.S. Pat. No. 9,205,304, the disclosure of which is hereby incorporated by reference. Preferably, the semi-transparent metallic coating comprises the pigment mixture composition in an amount of about 1% to about 30 wt. % based on total solids in the semi-transparent metallic coating. In another embodiment, the pigment is selected from the group consisting of: a) calcium aluminum borosilicate coated with a metal oxide; and b) silicon dioxide platelets coated with metal oxide; and mixtures thereof are used. Such mixtures are described in Morgan et al., U.S. Pat. No. 9,333,394, the disclosure of which is hereby incorporated by reference.
The decorative-effect coating layer can be a resin layer in which a material that provides the visual effect is dispersed in a resin such as an acrylic or polyurethane resin. Polyureas, acrylic polyurethanes, polyesters, polyester acrylics, and epoxies also can be used as resins in accordance with this invention. This resin is applied to the outer surface of the golf ball. In other embodiments, the decorative-effect layer may be a metal thin film containing a metal selected from aluminum, nickel, gold, platinum, chromium, iron, copper, tin, indium, silver, titanium, lead, zinc, or germanium, or alloys or compounds of the same, that is formed by vacuum deposition, sputtering, ion plating, or the like on a layer that constitutes the decorative film such as the transparent resin layer or the base layer. Such a thin metal film has high luster and, therefore, can provide particularly excellent visual effects.
In some embodiments, fluorescents can be used in the decorative-effect coating layer. Fluorescent materials useful in the present invention are commercially available fluorescent pigments and dyes. Some are described in U.S. Pat. Nos. 2,809,954; 2,938,873; 2,851,424; or 3,412,036, which are incorporated by reference herein. A commercial source for these products is Dayglo Color Corporation. As described in the cited patents, these fluorescent daylight materials are organic co-condensates. They are typically composed of melamine, an aldehyde such as formaldehyde, a heterocyclic compound and/or an aromatic sulfonamide. Typical of such materials is Solvent Yellow 44, compounds which are sold by DayGlo under the trademark Saturn Yellow and by Lawler under the trademark Lemon Yellow. The amount of fluorescent material to be used is largely a matter of choice depending on the brightness desired. However, it is preferred that the amount of fluorescent dye be from about 0.01% to about 0.5% by weight of the composition and the amount of fluorescent pigment be from about 0.5% to about 6% by weight of the composition.
In general, fluorescent dyes useful in the present invention include dyes from the thioxanthene, xanthene, perylene, perylene imide, coumarin, thioindigoid, naphthalimide and methine dye classes. Useful dye classes have been more completely described in U.S. Pat. No. 5,674,622, which is incorporated herein by reference in its entirety. Representative yellow fluorescent dye examples include, but are not limited to: Lumogen F Orange™ 240 (BASF, Rensselaer, N.Y.); Lumogen F Yellow™ 083 (BASF, Rensselaer, N.Y.); Hostasol Yellow™ 3G (Hoechst-Celanese, Somerville, N.J.); Oraset Yellow™ 8GF (Ciba-Geigy, Hawthorne, N.Y.); Fluorol 088™ (BASF, Rensselaer, N.Y.); Thermoplast F Yellow™ 084 (BASF, Rensselaer, N.Y.); Golden Yellow™ D-304 (DayGlo, Cleveland, Ohio); Mohawk Yellow™ D-299 (DayGlo, Cleveland, Ohio); Potomac Yellow™ D-838 (DayGlo, Cleveland, Ohio); and Polyfast Brilliant Red™ SB (Keystone, Chicago, Ill.).
In some embodiments, the visually enhancing means comprises edge-effect pigments. Edge-effect pigments are attracted to the edges or sharper contours of the surfaces to which they are applied and thus leave higher concentrations of pigment in such areas. Edge-effect pigments are sold by Bayer Co under the description “Fantasia Colors and Special Effects” and include Leda Edge-Effects. Edge-effect pigments are also sold by Merck Co under the tradenames Miraval, Iriodin, Colorstream, Xirallic, Solarflair, Lazerflair, and Florapearl.
The decorative-effect coating layer may additionally comprise pigment or dye in an amount sufficient to provide a hue to the material but maintain translucence. That is, the substantially transparent polymeric matrix may be lightly colored or tinted so long as the underlying layer remains visible. Suitable dyes include fluorescent dyes such as from the thioxanthene, xanthene, perylene, perylene imide, coumarin, thioindigoid, naphthalimide and methine dye classes. Useful dye classes have been more completely described in U.S. Pat. No. 5,674,622, which is incorporated herein by reference in its entirety. Representative yellow fluorescent dye examples include, but are not limited to: Lumogen F Orange™ 240 (BASF, Rensselaer, N.Y.); Lumogen F Yellow™ 083 (BASF, Rensselaer, N.Y.); Hostasol Yellow™ 3G (Hoechst-Celanese, Somerville, N.J.); Oraset Yellow™ 8GF (Ciba-Geigy, Hawthorne, N.Y.); Fluorol 088™ (BASF, Rensselaer, N.Y.); Thermoplast F Yellow™ 084 (BASF, Rensselaer, N.Y.); Golden Yellow™ D-304 (DayGlo, Cleveland, Ohio); Mohawk Yellow™ D-299 (DayGlo, Cleveland, Ohio); Potomac Yellow™ D-838 (DayGlo, Cleveland, Ohio) and Polyfast Brilliant Red™ SB (Keystone, Chicago, Ill.).
The decorative-effect coating layer may have a thickness of about 0.1 μm to about 50 μm. In preferred embodiments, the decorative-effect layer coating may have a thickness of about 1 μm to 45 μm, or from about 2 μm to 40 μm, or from about 4 μm to 30 μm. These coating layers have a thickness that is considerably less than the polymeric layers used to construct a traditional golf ball, for example, a two-piece, three-piece, four-piece, and five-piece golf balls as described above. Semi-transparent decorative-effect coating layers having a thickness in this range tend to have a good balance between reflecting and transmitting the incident light. In this way, the decorative-effect coating layer helps impart unique visual effects to the golf ball construction of this invention.
A transparent topcoat may be applied to the outer surface of the golf ball in accordance with the present invention. This transparent topcoat protects any printed indicia, provides high gloss, provides abrasion or wear-resistance, and generally enhances the overall aesthetics of the ball. As show in
The topcoat normally contains light stabilizers and optical brighteners, which both compete for absorption of the ultraviolet (UV) light. Optical brighteners absorb electromagnetic radiation in the ultraviolet portion of the spectrum and re-emit (i e., “fluoresce”) radiation in the visible portion of the spectrum. When applied to the exterior of a golf ball, optical brighteners enhance the whiteness and/or brightness of such balls. This whitening effect makes the materials appear less yellowish by increasing the overall amount of blue light reflected. In general, the brighteners are selected from one of the following classes: triazine-stilbenes (di, tetra-, or hexa-sulfonated); coumarins; imidazolines; diazoles; triazoles; benzooxazolines; and biphenyl-stilbenes; and mixtures thereof. The concentration of optical brighteners in the topcoat can be in the range of about 0.1 to about 5 weight percent based on the total weight of solids in the topcoat, and preferably in the range of about 0.5 to about 3.5 weight percent.
Light stabilizers protect against photodegradation initiated due to exposure to UV light. When the coating is exposed to UV radiation from the sunlight, this initiates degradation through a photo-oxidative process. Photo-oxidation is a chain-reaction process involving free radicals and hydroperoxide intermediates. Light stabilizers inhibit this process by absorption of the damaging UV radiation or by scavenging the reactive intermediates. Such stabilizers include ultraviolet (UV) absorbers which absorb ultraviolet radiation and have a high degree of inherent photostability; and hindred amine light stabilizers (HALs) which primarily function by scavenging the free-radical intermediates in the photo-oxidation process. These scavengers interrupt free radical reactions.
Suitable UV absorbers include, but are not limited to, triazines, benzoxazinones, benzotriazoles, benzophenones, benzoates, and the like. In some instances, light stabilizers such as Tinuvin® 571, 123, P, and 328, and 329 UV absorbers, commercially available from BASF, are included in the cover material. Adding the light stabilizers to the cover composition can help slow down discoloration due to exposure to the UV radiation. For example, the light stabilizers can be present in the cover composition in an amount in the range of about 1 to about 8 weight percent (wt. %) based on the weight of the composition. In other instances, the cover stock does not include any light stabilizers.
Preferably, the topcoat composition used for coating golf balls of this invention is a polyurethane, solvent-borne composition comprising a resin component and an isocyanate component. The Part A component of the coating preferably contains polyol, catalyst, solvent, UV absorbers, hindered amine light stabilizers, and optical brighteners as described further below. The Part B component of this coating preferably contains polyisocyanates such as hexamethylene diisocyanate, trimer of hexamethylene diisocyanate, or biuret of hexamethylene diisocyanate and solvents as also described further below. Aliphatic isocyanates are preferred since they have better ultraviolet (UV) light durability and lesser tendency to yellow when exposed to heat and light. The viscosity of the coating is adjusted using solvents including n-butyl acetate, t-butyl acetate, methyl amyl ketone (MAK), and ethyl acetate. Other solvent-borne formulations such as polyureas, acrylic polyurethanes, polyesters, polyester acrylics, and epoxies also can be used in accordance with this invention.
The transparent topcoat may have a thickness in the range of about 1 μm to about 50 μm. In preferred embodiments the transparent topcoat layer may have a thickness of about 2 μm to 40 μm, or from 4 μm to 30 μm.
Different materials may be used in the construction of the golf balls of the present invention. For example, the golf ball may contain a single- or multi-layered core. In one preferred embodiment, a core assembly comprising an inner core (center) and surrounding outer core layer is made. Thermoset or thermoplastic compositions may be used to form the inner core and outer core layers. In one preferred embodiment, at least one of the core layers is formed from a rubber composition. Preferably, the rubber composition comprises polybutadiene rubber. More particularly, in one version, the ball contains a dual-core comprising an inner core (center) and surrounding outer core layer, each layer made of a polybutadiene rubber composition.
Suitable rubber compositions for forming at least one of the core layers include, but are not limited to, rubber compositions comprising a rubber material such as, for example, polybutadiene, ethylene-propylene rubber, ethylene-propylene-diene rubber, polyisoprene, styrene-butadiene rubber, polyalkenamers, butyl rubber, halobutyl rubber, or polystyrene elastomers. For example, thermoset rubber compositions containing polybutadiene rubber may be used to form both the inner core (center) and surrounding outer core layer in a dual-layered construction. In another version, at least one of the core layers is formed from a thermoplastic composition. For example, ionomer compositions comprising an ethylene acid copolymer containing acid groups such that less than 70% of the acid groups are neutralized (partially neutralized polymers) may be used. In another example, ionomer compositions comprising an ethylene acid copolymer containing acid groups such that greater than 70% of the acid groups are neutralized (highly neutralized polymers or HNPs) may be used. For example, thermoplastic ionomer compositions may be used to form both the inner core (center) and surrounding outer core layer in a dual-layered construction. In another example, a thermoset rubber composition may be used to form the inner core and a thermoplastic ionomer composition may be used to form the outer core. In yet another example, a thermoplastic ionomer composition may be used to form the inner core and a thermoset rubber composition may be used to form the outer core layer.
In one preferred embodiment, an intermediate layer is disposed between the single or multi-layered core and surrounding cover layer. These intermediate layers also can be referred to as casing or inner cover layers. The intermediate layer can be formed from any materials known in the art, including thermoplastic and thermosetting materials, but preferably is formed of an ionomer composition comprising an ethylene acid copolymer containing acid groups that are at least partially neutralized. Suitable ethylene acid copolymers that may be used to form the intermediate layers are generally referred to as copolymers of ethylene; C3 to C8 α, β-ethylenically unsaturated mono-or dicarboxylic acid; and optional softening monomer.
The golf ball may contain one or more cover layers. For example, a golf ball having a single-layered cover may be made. In another version, a golf ball having a two-layered cover including inner and outer cover layers may be made.
The cover layers of this invention provide the ball with a variety of advantageous mechanical and playing performance properties as well as aesthetic and decorative properties as discussed above. In general, the hardness and thickness of the different cover layers may vary depending upon the desired ball construction. In addition, as discussed above, an intermediate layer may be disposed between the core and cover layers. The cover layers preferably have high impact durability, toughness, and wear-resistance. The cover layers help players to generate high ball velocity off the tee and achieve long distances with their drives. At the same time, the cover layers provide the player with a more comfortable and natural feeling when striking the ball with a club. The cover layers help provide good spin control.
Suitable conventional materials that can be used to form a cover layer include, but are not limited to, polyurethanes; polyureas; copolymers, blends and hybrids of polyurethane and polyurea; olefin-based copolymer ionomer resins (for example, Surlyn® ionomer resins and DuPont HPF® 1000, HPF® 2000, and HPF® 1035; and HPF® AD 1172, commercially available from DuPont; Iotek® ionomers, commercially available from ExxonMobil Chemical Company; Amplify® IO ionomers of ethylene acrylic acid copolymers, commercially available from The Dow Chemical Company; and Clarix® ionomer resins, commercially available from A. Schulman Inc.); polyethylene, including, for example, low density polyethylene, linear low density polyethylene, and high density polyethylene; polypropylene; rubber-toughened olefin polymers; acid copolymers, for example, poly(meth)acrylic acid, which do not become part of an ionomeric copolymer; plastomers; flexomers; styrene/butadiene/styrene block copolymers; styrene/ethylene-butylene/styrene block copolymers; dynamically vulcanized elastomers; copolymers of ethylene and vinyl acetates; copolymers of ethylene and methyl acrylates; polyvinyl chloride resins; polyamides, poly(amide-ester) elastomers, and graft copolymers of ionomer and polyamide including, for example, Pebax® thermoplastic polyether block amides, commercially available from Arkema Inc; cross-linked trans-polyisoprene and blends thereof; polyester-based thermoplastic elastomers, such as Hytrel®, commercially available from DuPont or RiteFlex®, commercially available from Ticona Engineering Polymers; polyurethane-based thermoplastic elastomers, such as Elastollan®, commercially available from BASF; synthetic or natural vulcanized rubber; and combinations thereof. Polyurethanes, polyureas, and hybrids of polyurethanes-polyureas are particularly desirable because these materials can be used to make a golf ball having high resiliency and a soft feel. By the term, “hybrids of polyurethane and polyurea,” it is meant to include copolymers and blends thereof.
The resulting golf ball of this invention comprising the base (sub-coating) layer, for example a layer having a concavo-convex surface pattern; an optional semi-transparent metallic layer; an optional semi-transparent decorative effect layer; and a transparent topcoat layer, as described above, provides a golf ball having a visually distinct and aesthetically pleasing appearance. The golf ball cover structure of this invention is able to scatter the visible light rays in different directions to produce unique visuals. The different metallic and special effect materials in the semi-transparent layers help provide the ball with unique ornamental affects without sacrificing the playing performance properties of the ball such as resiliency and spin control. This combination of layers provides a unique, visually distinct appearance as light is reflected in a much more random, less uniform manner than prior art golf balls. The golf balls of this invention are aesthetically pleasing and provide a creative look.
When numerical lower limits and numerical upper limits are set forth herein, it is contemplated that any combination of these values may be used. Other than in the operating examples, or unless otherwise expressly specified, all of the numerical ranges, amounts, values and percentages such as those for amounts of materials and others in the specification may be read as if prefaced by the word “about” even though the term “about” may not expressly appear with the value, amount or range. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the present invention.
It is understood that the manufacturing methods, compositions, constructions, and products described and illustrated herein represent only some embodiments of the invention. It is appreciated by those skilled in the art that various changes and additions can be made to the methods, compositions, constructions, and products without departing from the spirit and scope of this invention. It is intended that all such embodiments be covered by the appended claims.
This application claims the benefit of U.S. Provisional Application No. 63/125,080, filed Dec. 14, 2020, the entire disclosure of which is incorporated by reference.
| Number | Date | Country | |
|---|---|---|---|
| 63125080 | Dec 2020 | US |
